Turbomachine type chemical reactor

ABSTRACT

A turbomachine type chemical reactor for processing a process fluid is presented. The turbomachine type chemical reactor includes at least one impeller section and a stationary diffuser section arranged downstream. The impeller section accelerates the process fluid to a supersonic flow. A shock wave is generated in the stationary diffuser section that instantaneously increases static temperature of the process fluid downstream the shock wave for processing the process fluid. which allows thermally cracking a chemical compound, such as hydrocarbon, in the process fluid. Static pressure of the process fluid is simultaneously increased across the shock wave. The turbomachine type chemical reactor significantly reduces residence time of the process fluid in the chemical reactor and improves efficiency of the chemical reactor.

TECHNICAL FIELD

Disclosed embodiments relate generally to a turbomachine type chemicalreactor, in particular, a turbomachine type chemical reactor forprocessing a process flow, more in particular, a turbomachine typechemical reactor for an endothermic process of a process fluid.

DESCRIPTION OF THE RELATED ART

An endothermic process may refer to a process that requires addition ofheat to a process fluid to promote occurrence of endothermic chemicalreactions. It may be used in oil refineries and petrochemical plants forfractioning or “cracking” heavier molecular weight hydrocarbons. Aftercracking, the lighter molecular weight hydrocarbons are used in thepetrochemical industry as feedstock for production of other chemicalcompounds. In known, commercially practiced, pyrolysis-crackingprocesses, application of heat and pressure in furnace-type, chemicalreactors, in low oxygen environments, fractionalizes heavier molecularweight hydrocarbons into various lighter molecular weight olefins, suchas ethylene, without causing combustion. Another example of anendothermic process may be steam reforming of methane. Often, theheavier molecular weight hydrocarbon is entrained in heated steam. Thesteam-and hydrocarbon-containing process fluid flows through heatexchangers of the chemical reactor. Imparted temperature and residencetime of the process fluid within heat exchangers are controlled tofracture the entrained hydrocarbons to the desired output, lowermolecular weight hydrocarbons.

Using the example of ethylene production by pyrolysis, a process fluidcomprising hydrocarbon and steam mixture is heated from 1220° F. to1545° F. in less than 400 milliseconds (ms), in a furnace-type chemicalreactor. The rate at which the heating is done and subsequently quenched(to halt further chemical reactions) is important for the production ofthe desired blend of hydrocarbons. Oxygen must not be present during theheating process, in order to avoid hydrocarbon combustion. The reactionprocess in the furnace-type chemical reactor requires large heat inputand relatively slow mass flow rate of the process fluid. In order tomeet output production goals, ethylene production plants employmultiple, parallel pyrolysis reactors, each requiring large thermalenergy inputs. Each additional reactor needed to meet production goalsincreases capital spending, energy consumption to heat the processfluid, plant real estate space.

It is desirable to increase mass flow of process fluid during thehydrocarbon cracking process, with lower production energy input.Increased mass flow meets production goals with less plant equipmentcapital spending and real estate space.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the application are explained in further detailwith respect to the accompanying drawings. In the drawings:

FIG. 1 is a schematic longitudinal section view of a chemical reactoraccording to an embodiment;

FIG. 2 is a schematic process diagram of a process fluid flowing througha flow path of the chemical reactor shown in FIG. 1 according to anembodiment;

FIG. 3 is a schematic perspective view of the chemical reactor of FIG.1, with outer casing removed for clarity purpose;

FIG. 4 is a schematic section view of an impeller blade according to anembodiment;

FIG. 5 is a schematic view of a diffuser flow passage according to anembodiment;

FIG. 6 is a schematic perspective view of an exhaust flow passageaccording to an embodiment;

FIG. 7 is a schematic longitudinal section view of a chemical reactoraccording to another embodiment;

FIG. 8 is a schematic process diagram of a process fluid flowing througha flow path of the chemical reactor shown in FIG. 7;

FIG. 9 is a schematic longitudinal section view of a chemical reactoraccording to a further embodiment;

FIG. 10 is a schematic process diagram of a process fluid flowingthrough a flow path of the chemical reactor shown in FIG. 9;

FIG. 11 is schematic process diagram of a process fluid flowing througha flow path of a chemical reactor and a chart of calculated staticpressure and temperature of the process fluid at various locations alongthe flow path of the chemical reactor according to an embodiment; and

FIG. 12 is a schematic longitudinal section view of a chemical reactoraccording to another further embodiment.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures.

DETAILED DESCRIPTION

A detailed description related to aspects of disclosed embodiments isdescribed hereafter with respect to the accompanying figures.

For illustration purpose, term “axial” or “axially” refers to adirection along a longitudinal axis of a chemical reactor, term “radial”or “radially” refers to a direction perpendicular to the longitudinalaxis of the chemical reactor, term “downstream” or “aft” refers to adirection along a flow direction, term “upstream” or “forward” refers toa direction against the flow direction.

FIG. 1 illustrates a schematic longitudinal section view of a chemicalreactor 10 according to an embodiment. In this embodiment, the chemicalreactor 10 is a single stage chemical reactor 10 having one impellersection 200 and one stationary diffuser section 400. The impellersection 200 and the stationary diffuser section 400 function like aturbomachine. As shown in FIG. 1, the chemical reactor 10 includes anouter casing 100 enclosing a plurality of components along alongitudinal axis 12. The component includes the impeller section 200and the stationary diffuser section 400. The outer casing 100 has a flowinlet 110 for intaking process fluid F. The outer casing 100 has a flowexit 120 for exiting the process fluid F. The flow inlet 110 and theflow exit 120 may have radial or axial orientation. In the exemplaryembodiment of FIG. 1, the flow inlet 110 has a radial orientation andthe flow exit 120 has an axial orientation. It is understood that theflow inlet 110 and the flow exit 120 may have any combinations of radialor axial orientations.

The outer casing 100 has an inner shroud 130 extending in the axialdirection. An annual flow path 140 is defined within the outer casing100 axially along the inner shroud 130 between the flow inlet 110 andthe flow exit 120. The process fluid F enters the flow path 140 via theflow inlet 110 and exits the flow path 140 via the flow exit 120defining an axial flow path. For example, a chemical compound, such ashydrocarbon in the process fluid F, is thermally cracked while theprocess fluid F flows through the flow path 140.

The chemical reactor 10 includes a rotary shaft 14 axially extendinginto the outer casing 100. The rotary shaft is connected to a powersupply 16 that drives and rotates the rotary shaft 14 in a rotationdirection R around the longitudinal axis 12. In the exemplary embodimentshown in FIG. 1, the rotation direction R is clockwise. It is understoodthat the rotation direction R can be counterclockwise in otherembodiments. The power supply 16 includes an electric motor, a steamturbine, a gas turbine, or any combustion engine or power supplies knownin the industrial.

Referring to FIG. 1, the impeller section 200 includes a plurality ofrotating impeller blades 210 positioned on a rotor disk 220. Therotating impeller blades 210 may be manufactured integral to the rotordisk 220 as one component. Alternatively, the rotating impeller blades210 may be manufactured separately and mounted on the rotor disk 220.The rotor disk 220 is coupled to the rotary shaft 14. The rotatingimpeller blades 210 are circumferentially spaced apart from each otherand extends radially outwardly from the rotor disk 220 into the flowpath 140. The flow path 140 is formed between the rotor disk 220 and theinner shroud 130 of the outer casing 100. The impeller section 200 isdesigned to accelerate the process fluid F in the flow path 140 to asupersonic flow having a Mach number M that is greater than 1.

The stationary diffuser section 400 is arranged downstream of theimpeller section 200. The stationary diffuser section 400 has adivergent shape. The stationary diffuser section 400 includes aplurality of stationary diffuser vanes 410 positioned on a stationarydiffuser hub 420. The stationary diffuser vanes 410 may be manufacturedintegral to the stationary diffuser hub 420 as one component.Alternatively, the stationary diffuser vanes 410 may be manufacturedseparately and mounted on the stationary diffuser hub 420. Thestationary diffuser vanes 410 are circumferentially spaced apart fromeach other and extends radially outwardly from the stationary diffuserhub 420 into the flow path 140. The flow path 140 is formed between thestationary diffuser hub 420 and the inner shroud 130 of the outer casing100. A shock wave 416 (shown in FIG. 2) is generated in the stationarydiffuser section 400 by applying an appropriate back pressure at an exitof the stationary diffuser section 400.

The chemical reactor 10 includes an exhaust section 500 arrangeddownstream of the stationary diffuser section 400. The exhaust section500 includes a plurality of stationary exhaust vanes 510 positioned on astationary exhaust hub 520. The stationary exhaust vanes 510 may bemanufactured integral to the stationary exhaust hub 520 as onecomponent. Alternatively, the stationary exhaust vanes 510 may bemanufactured separately and mounted on the stationary exhaust hub 520.The stationary exhaust vanes 510 are circumferentially spaced apart fromeach other and extends radially outwardly from the stationary exhausthub 520 into the flow path 140. The flow path 140 is formed between thestationary exhaust hub 520 and the inner shroud 130 of the outer casing100. The exhaust section 500 includes an exhaust cone 522 and an exittransition 524 arranged downstream of the stationary exhaust vanes 510.The flow path 140 axially extends through a passage between the exhaustcone 522 and the exit transition 524 and exits the outer casing 100 atthe flow exit 120.

FIG. 2 is a schematic process diagram of the process fluid F flowingthrough the flow path 140 of the chemical reactor 10 shown in FIG. 1.The process fluid F enters the flow path 140 via the flow inlet 110. Theprocess fluid F axially flows through the impeller section 200 and isaccelerated to a supersonic flow. The supersonic process fluid F isdirected into the stationary diffuser section 400 and is decelerated toa subsonic flow having a Mach number M that is less than 1 across theshock wave 416. The shock wave 416 instantaneously significantlyincreases a static temperature T of the process fluid F downstream ofthe shock wave 416 which generates sufficient heat to, for example,crack hydrocarbon in the process fluid F. The shock wave 416simultaneously and instantaneously increased a static pressure P of theprocess fluid F downstream of the shock wave 416 which generates adesired outlet pressure of the chemical reactor 10. The process fluid Fis directed into the exhaust section 500 and exits the flow path 140 viathe flow exit 120.

FIG. 3 is a schematic perspective view of the chemical reactor 10 shownin FIG. 1. The outer casing 100 is removed in FIG. 3 for claritypurpose. FIG. 4 is a schematic view of the rotating impeller blade 210.FIG. 5 is a schematic view of adjacent stationary diffuser vanes 410.FIG. 6 is a schematic view of adjacent stationary exhaust vanes 510.

Referring to FIG. 1, FIG. 3 and FIG. 4, the impeller section 200includes a plurality of rotating impeller blades 210 positioned on therotor disk 220. The rotating impeller blades 210 are circumferentiallyspaced apart from each other and extend radially outwardly from therotor disk 220 into the flow path 140. As shown in FIG. 4, each rotatingimpeller blade 210 has a leading edge 211 facing upstream and a trailingedge 212 facing downstream. Each rotating impeller blade 210 has aconcave side 213 and a convex side 214 between the leading edge 211 andthe trailing edge 212. Upon rotating by the rotor disk 220, the rotatingimpeller blades 210 accelerate the process fluid F by changing a flowdirection of the process fluid F from a direction 215 at the leadingedge 211 to a direction 216 at the trailing edge 212. The flow direction215 at the leading edge 211 flow and the flow direction 216 at thetrailing edge 212 are tangential relative to the longitudinal axis 12.The rotating impeller blades 210 have supersonic blade profiles. Therotating impeller blades 210 accelerate the process fluid F to asupersonic flow at the trailing edge 212. Acceleration rate of theprocess fluid F is determined by an amount of the flow direction change.The higher rate the process fluid F accelerates, the larger amount theflow direction changes from the leading edge 211 to the trailing edge212. Static pressure and temperature of the process fluid F are notsignificantly changed at the trailing edge 212 compared to at theleading edge 211.

Referring to FIG. 1, FIG. 3 and FIG. 5, the supersonic process fluid Fis discharged from the impeller section 200 into the stationary diffusersection 400. The stationary diffuser section 400 includes a plurality ofstationary diffuser vanes 410 positioned on a stationary diffuser hub420. The stationary diffuser vanes 410 are circumferentially spacedapart from each other and extends radially outwardly from the stationarydiffuser hub 420 into the flow path 140. As shown in FIG. 5, eachstationary diffuser vane 410 has a leading edge 411 facing upstream anda trailing edge 412 facing downstream. Each stationary diffuser vane 410has two opposing sides 413 and 414 between the leading edge 411 and thetrailing edge 412. A diffuser flow passages 415 is formedcircumferentially between adjacent stationary diffuser vanes 410 andradially between the stationary diffuser hub 420 and the inner shroud130. A cross sectional area D_(A) of the diffuser flow passage 415 isdetermined by a cross sectional height D_(H) and a cross sectional widthD_(W) of the diffuser flow passage 415. The cross sectional height D_(H)of the diffuser flow passage 415 is defined radially between thestationary diffuser hub 420 and the inner shroud 130. The crosssectional width D_(W) of the diffuser flow passage 415 is definedcircumferentially between adjacent facing sides 413 and 414 of theadjacent stationary diffuser vanes 410. The diffuser flow passage 415 isdesigned as divergent along the axial direction.

A shock wave 416 of the process fluid F is generated at an axiallocation in the stationary diffuser section 400 by applying anappropriate back pressure at an exit of the stationary diffuser section400, in this embodiment, at the trailing edge 412 of the stationarydiffuser vane 410. The supersonic process fluid F continuouslyaccelerates along the divergent stationary diffuser section 400 as thecross sectional area D_(A) of the diffuser flow passage 415 gets larger.The region of the supersonic acceleration of the process fluid F isterminated by the shock wave 416. The axial location of the shock wave416 in the stationary diffuser section 400 is a function of the backpressure. The lower the back pressure is, the further downstream theaxial location of the shock wave 416 is, the longer the region of thesupersonic acceleration of the process fluid F is. By adjusting adivergent rate of the diffuser flow passage 415, or by adjusting theback pressure at the trailing edge 412 of the stationary diffuser vane410, or by adjusting both, the process fluid F may achieve a highsupersonic Mach number M upstream the shock wave 416. The divergent rateof the diffuser flow passage 415 can be adjusted by adjusting the crosssectional area D_(A) of the diffuser flow passage 415 along the axialdirection, which can be achieved by adjusting the cross sectional heightD_(H) of the diffuser flow passage 415 along the axial direction, or byadjusting the cross sectional width D_(W) of the diffuser flow passage415 along the axial direction, or by adjusting both.

Still referring to FIG. 1, FIG. 3 and FIG. 5, the stationary diffuservanes 410 may have a helical profile. The process fluid F swirls whenpassing through the diffuser flow passage 415 formed between theadjacent helical stationary diffuser vanes 410. The high accelerated andswirled process fluid F in the stationary diffuser section 400 upstreamthe shock wave 416 may be segregated into components having differentmolecule weights due to the high centrifugal force in the stationarydiffuser section 400. Components in the process fluid F having lowmolecule weights, such as hydrogen, flow in a low radial position in thediffuser flow passage 415 toward the stationary diffuser hub 420.Components in the process fluid F having high molecule weights, such asCO₂, hydrocarbon, or steam, flow in a high radial position in thediffuser flow passage 415 toward the inner shroud 130. The stationarydiffuser section 400 may include at least one aperture 421 arranged onthe stationary diffuser hub 420 downstream the shock wave 416. The lowmolecule weight components in the process fluid F may be extractedthrough the aperture 421 and removed from the process fluid F for theremaining flow path 140. A plurality of apertures 421 may be arranged onthe stationary diffuser hub 420 downstream the shock wave 416.

The shock wave 416 instantaneously decreases the supersonic processfluid F to a subsonic process fluid F across the shock wave 416. Astatic temperature of the process fluid F is instantaneously increasedacross the shock wave 416. A static pressure of the process fluid F issimultaneously and instantaneously increased across the shock wave 416.The increased static temperature of the process fluid F downstream theshock wave 416 generates enough heat to, for example, crack the heaviermolecular weight hydrocarbons in the process fluid F. The shock wave 416significantly reduces the heating and pressurization process time of theprocess fluid F and thus significantly reduces residence time of theprocess fluid F within the chemical reactor 10. A ratio of the statictemperature and a ratio of the static pressure across the shock wave 416is a function of the upstream Mach number M of the process fluid F andproperty of the process fluid.

Referring to FIG. 1, FIG. 3 and FIG. 6, the subsonic process fluid F isdischarged from the diffuser section 400 to the stationary exhaust vanes510 in the exhaust section 500. As shown in FIG. 6, each stationaryexhaust vane 510 has a leading edge 511 facing upstream and a trailingedge 512 facing downstream. Each stationary exhaust vane 510 has twoopposing sides 513 and 514 between the leading edge 511 and the trailingedge 512. A plurality of exhaust flow passages 515 are formed betweenadjacent stationary exhaust vanes 510 and between the stationary exhausthub 520 and the inner shroud 130. A cross sectional area E_(A) of theexhaust flow passage 515 is determined by a cross sectional height E_(H)and a cross sectional width E_(W) of the exhaust flow passage 515. Thecross sectional height E_(H) of the exhaust flow passage 515 is definedradially between the stationary exhaust hub 520 and the inner shroud130. The cross sectional width E_(W) of the exhaust flow passage 515 isdefined circumferentially between adjacent facing sides 513 and 514 ofthe adjacent stationary exhaust vanes 510. The exhaust flow passage 515is designed as convergent along the axial direction. By adjusting aconvergent rate of the exhaust flow passage 515, an appropriate backpressure may be applied at the exit of the stationary diffuser section400. A desired supersonic Mach number M of the process fluid F can beachieved upstream of the shock wave 416, as noted above. The convergentrate of the exhaust flow passage 515 can be adjusted by adjusting thecross sectional area E_(A) of the exhaust flow passage 515 along theaxial direction, which can be achieved by adjusting the cross sectionalheight E_(H) of the exhaust flow passage 515 along the axial direction,or by adjusting the cross sectional width E_(W) of the exhaust flowpassage 515 along the axial direction, or by adjusting both.

The process fluid F is discharged from the stationary exhaust vane 510to the flow path 140 between the exhaust cone 522 and the exittransition 524 to the flow exit 120. According to another embodiment,the process fluid F may also be discharged from the stationary exhaustvanes 510 to another stage of the chemical reactor 10 for furtherprocessing. The stationary exhaust vanes 510 may align the flowdirection of the process fluid F exiting the first stage with theleading edges 211 of the rotating impeller blades 210 of another stage.

Referring to FIG. 1, the chemical rector 10 includes a quenching zone150 arranged downstream of the impeller section 200. The quenching zone150 includes at least one nozzle 152. The nozzle 152 is in fluidcommunication with the process fluid F. The nozzle 152 may introducecoolant flow into the process fluid F for stabilizing temperature of theprocess fluid F. The nozzle 152 may also introduce anti-fouling fluidinto the process fluid F for inhibiting fouling within the chemicalreactor 10.

FIG. 7 is a schematic longitudinal section view of a chemical reactor 10according to an embodiment. In this embodiment, the chemical reactor 10is a single stage chemical reactor 10 having dual impeller sections 200and one stationary diffuser section 400. A stationary bucket section 300is arranged between the dual impeller sections 200. The stationarybucket section 300 includes a plurality of stationary bucket vanes 310positioned on a stationary bucket vane hub 320. The stationary bucketvanes 310 may be manufactured integral to the stationary bucket vane hub320 as one component. Alternatively, the stationary bucket vanes 310 maybe manufactured separately and mounted on the stationary bucket vane hub320. The stationary bucket vanes 310 are circumferentially spaced apartfrom each other and extends radially outwardly from the stationarybucket hub 320 into the flow path 140. Each stationary bucket vane 310has a leading edge 311 facing upstream and a trailing edge 312 facingdownstream. The stationary bucket vanes 310 align the flow direction ofthe process fluid F exiting from the trailing edge 212 of the upstreamrotating impeller blade 210 with the leading edge 211 of the downstreamrotating impeller blade 210. The downstream impeller section 200 mayfurther accelerate the velocity of the process fluid F prior to enteringthe stationary diffuser section 400. The rotating impeller blades 210 ineach impeller section 200 may have the same or different configurations.The chemical reactor 10 having dual impeller sections 200 may reduce theinlet velocity of the process fluid F at the flow inlet 110 compared toa chemical reactor 10 having one impeller section 200. The chemicalreactor 10 having dual impeller sections 200 may reduce velocity of theprocess fluid F at the flow inlet 120 and may require less flowdirection changing in the rotating impeller blades 210 compared to achemical reactor 10 having one impeller section 200. FIG. 8 is aschematic process diagram of the process fluid flowing through the flowpath 140 of the dual impeller single stage chemical reactor 10 shown inFIG. 7.

FIG. 9 illustrates a schematic longitudinal section view of a chemicalreactor 10 according to an embodiment. In this embodiment, the chemicalreactor 10 is a two-stage chemical reactor 10. The two-stage chemicalreactor 10 includes an upstream stage and a downstream stage. Each stagehas one impeller section 200 and one stationary diffuser section 400. Itis understood that each stage or one of the two stages may have dualimpeller sections 200 and one stationary diffuser section 400 asillustrated in FIG. 7 and FIG. 8. The two stages may be enclosed withina common outer casing 100. Alternatively, the two stages may also beenclosed within two separate outer casings 100. The two-stage chemicalreactor 10 generates an upstream shock wave 416 and a downstream shockwave 416 in the upstream stage and the downstream stage respectively toimprove cracking process of the process fluid F. The two-stage chemicalreactor 10 may reduce velocity of the process fluid F at the flow inlet120 and may require less flow direction changing in the rotatingimpeller blades 210. FIG. 10 is a schematic process diagram of theprocess fluid F flowing through the flow path 140 of the two-stagechemical reactor 10 shown in FIG. 9.

Referring to FIG. 9, the upstream stationary diffuser section 400includes at least one aperture 421 arranged on the stationary diffuserhub 420 downstream of the upstream shock wave 416. Low molecule weightcomponents in the process fluid F are extracted through the aperture 421and removed from the process fluid F for the remaining flow path 140.The process fluid F having the high molecule weight components flowsinto the downstream stage for further process. Efficiency of thechemical reactor 10 is significantly improved.

FIG. 11 is a schematic process diagram of the process fluid F flowingthrough the flow path 140 of the chemical reactor 10 having of dualimpeller sections 200 as shown in FIG. 8. A chart of calculated statictemperature T and static pressure P of the process fluid F at variouslocations along the flow path 140 is disposed below the process diagram.The chart of the calculated static temperature T and static pressure Pof the process fluid F at various locations along the flow path 140shown in FIG. 11 is for illustration purpose only. It is understood thatvalues of the static temperature T and static pressure P of the processfluid F at various locations along the flow path 140 vary correspondingto different geometries of the chemical rector 10 and property of theprocess fluid F. For example, the process fluid F is ahydrocarbon-containing process fluid.

As shown in FIG. 11, the static temperature and the static pressure Pare simultaneously and instantaneously increased across the shock wave416. As noted above, by tailoring geometry of the chemical reactor 10,such as the profile of the rotating impeller blades 210, the divergentrate of the diffuser flow passage 415, the convergent rate of theexhaust flow passage 515, a desired ratio of the static temperature Tand a desired ratio of the static pressure P across the shock wave 416are achieved to, for example, thermally crack the hydrocarbons in theprocess fluid F. For example, a ratio of the static temperature T acrossthe shock wave 416 may be increased by at least ten percent (10%). Aratio of the static pressure P across the shock wave 416 may beincreased by less than ten percent (10%), or by at least ten percent(10%), or by as much as twice or three times. The total increase of thestatic pressure P across the chemical reactor 10 is less than the staticpressure P increased across the shock wave 416. The residence time inthe chemical reactor 10 is significantly reduced, for example in anorder of 10 milliseconds, or in an order of 5 milliseconds, or even inan order of 1 millisecond, compared to hundreds of milliseconds withinknown commercially practiced chemical reactors, such as furnace-typechemical reactor. The simultaneous heating and pressurization of theprocess fluid F across the shock wave 416 in the turbomachine typechemical reactor 10 may reduce gas compressors and heat exchangers whichare used in a furnace-type chemical reactor and thus reduces the costand complexity of an oil refinery and petrochemical plant and improvesreliability of the oil refinery and petrochemical plant.

The process fluid F exiting the stationary diffuser section 400 isdirected to the stationary exhaust vane 510 of the exhaust section 500.Cracking reaction may continue through the stationary exhaust vane 510.The cracking reaction may absorb heat from the process fluid F which mayeffectively stop chemical reactions in the process fluid F and reducestemperature of the process fluid F downstream of the shock wave 416. Theprocess fluid F may exit the chemical reactor 10 at the flow exit 120for a single stage chemical reactor 10. Alternatively, the process fluidF may enter a second stage for a two-stage chemical reactor 10 asillustrated in FIGS. 9 and 10, in which the process fluid F isre-accelerated to a supersonic flow, simultaneously and instantaneouslyincrease the static temperature T and the static pressure P across asecond shock wave 416 in the second stage which is similar asillustrated in FIG. 11. A quenching zone 150 may be incorporated in thesecond stage reactor downstream of the second impeller section 200 tocontrol the cracking reaction rate by injection of cooling steam orother cooling and/or anti-fouling fluids into the flow path 140.

FIG. 12 is a schematic longitudinal section view of a chemical reactor10 according to an embodiment. In this exemplary embodiment, the powersupply 16 is a gas turbine 16. A recuperator 17 is operatively connectedto the gas turbine 16 to extract the gas turbine exhaust gas to preheatthe process fluid F. The exhaust gas is then passed to a stack. Aheating device 18 may be operatively connected to the recuperator 17 tofurther heat the process fluid F. The heating device 18 may be afurnace, or any types of heating device known in the industry. Theheated process fluid F is then introduced to the flow inlet 110 of thechemical reactor 10, as illustrated above with references of FIGS. 1 to11. Such arrangement utilizes waste heat from the gas turbine 10 andimproves efficiency of the cracking process of the process fluid F.

According to an aspect, the proposed chemical reactor 10 is aturbomachine type chemical reactor for thermally cracking a chemicalcompound in a process fluid, such as hydrocarbons in process fluid F inan oil refinery and petrochemical plant. The proposed turbomachine typechemical reactor 10 includes at least one impeller section 200 and astationary diffuser section 400 to generate a shock wave 416 in thestationary diffuser section 400. The shock wave 416 instantaneouslyincreases the static temperature T of the process fluid F downstream ofthe shock wave 416 for cracking the process fluid F. The proposedturbomachine type chemical reactor 10 significantly reduces residencetime of process fluid F in the chemical reactor 10 and improves theefficiency of the chemical reactor 10.

According to an aspect, the proposed turbomachine type chemical reactor10 provides simultaneous heating and pressurization of process fluid Facross the shock wave 416. The proposed turbomachine type chemicalreactor 10 may reduce gas compressors and heat exchangers which are usedin a furnace-type chemical reactor. The proposed turbomachine typechemical reactor 10 is significantly more compact compared tofurnace-type chemical reactor. The proposed turbomachine type chemicalreactor 10 thus reduces the cost and complexity of an oil refinery andpetrochemical plant and improves reliability of the oil refinery andpetrochemical plant.

Although various embodiments that incorporate disclosed concepts havebeen shown and described in detail herein, those skilled in the art canreadily devise many other varied embodiments that still incorporatethese disclosed concepts. Disclosed embodiments are not limited to thespecific details of construction and the arrangement of components setforth in the description or illustrated in the drawings. Disclosedconcepts may be implemented by other implementations, and of beingpracticed or of being carried out in various ways, which now wouldbecome apparent to one skilled in the art. Also, it is to be understoodthat the phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. Unless specified or limited otherwise, theterms “mounted,” “connected,” “supported,” and “coupled” and variationsthereof are used broadly and encompass direct and indirect mountings,connections, supports, and couplings. Further, “connected” and “coupled”are not restricted to physical or mechanical connections or couplings.

REFERENCE LIST

-   10: Chemical Reactor-   12: Longitudinal Axis-   14: Rotary Shaft-   16: Power Supply-   17: Recuperator-   18: Heating Device-   100: Outer Casing-   110: Flow Inlet-   120: Flow Exit-   130: Inner Shroud-   140: Flow Path-   150: Quenching Zone-   152: Discharge Nozzle-   200: Impeller Section-   210: Rotating Impeller Blade-   211: Leading Edge of Blade-   212: Trailing Edge of Blade-   213: Concave Side of Rotating Impeller Blade-   214: Convex Side of Rotating Impeller Blade-   215: Leading Edge Flow Direction-   216: Trailing Edge Flow Direction-   220: Rotor Disk-   300: Stationary Bucket Section-   310: Stationary Bucket Vane-   311: Leading Edge of Stationary Bucket Vane-   312: Trailing Edge of Stationary Bucket Vane-   320: Stationary Bucket Vane Hub-   400: Stationary Diffuser Section-   410: Stationary Diffuser Vane-   411: Leading Edge of Stationary Diffuser Vane-   412: Trailing Edge of Stationary Diffuser Vane-   413, 414: Opposing Sides of Stationary Diffuser Vane-   415: Diffuser flow passage-   416: Shock Wave-   420: Stationary Diffuser Vane Hub-   421: Aperture-   500: Exhaust Section-   510: Stationary Exhaust Vane-   511: Leading Edge of Stationary Exhaust Vane-   512: Trailing Edge of Stationary Exhaust Vane-   513, 514: Opposing Sides of Stationary Exhaust Vane-   515: Exhaust flow passage-   520: Stationary Exhaust Vane Hub-   522: Exhaust Cone-   524: Exit Transition

What is claimed is:
 1. A chemical reactor to process a process fluid,the chemical reactor comprising: an outer casing comprising a flow inletfor intaking the process fluid and a flow outlet for exiting the processfluid, wherein a flow path is defined within the outer casing extendingaxially along an inner shroud of the outer casing between the flow inletand the flow outlet; a rotary shaft extending into the outer casing andcoupled to a rotor disk, wherein the rotor shaft is driven by a powersupply; a first impeller section and a second impeller section arrangeddownstream of the first impeller section, each impeller sectioncomprising a respective plurality of rotating impeller blades positionedon the rotor disk, wherein the plurality of rotating impeller bladesextends radially outwardly from the rotor disk into the flow path; astationary bucket section arranged between the first impeller sectionand the second impeller section; a stationary diffuser section arrangeddownstream of the second impeller section, wherein the stationarydiffuser section comprises a plurality of divergent diffuser flowpassages; an exhaust section arranged downstream of the stationarydiffuser section, wherein the exhaust section comprises a plurality ofconvergent exhaust flow passages wherein the respective plurality ofrotating impeller blades is configured to accelerate the process fluidto a supersonic flow, wherein the plurality of convergent exhaust flowpassages is configured to provide a back pressure such that a shock waveis generated in the stationary diffuser section, wherein the shock wavegenerated in the stationary diffuser section increases a statictemperature of the process fluid downstream of the shock wave togenerate sufficient heat to process the process fluid, wherein theplurality of diffuser flow passages is configured to provide a flowproperty of the process fluid across the shock wave for processing theprocess fluid.
 2. The chemical reactor as claimed in claim 1, whereinthe flow property of the process fluid comprises a ratio of statictemperature of the process fluid across the shock wave, wherein theratio of the static temperature of the process fluid across the shockwave is increased by at least ten percent.
 3. The chemical reactor asclaimed in claim 1, wherein the flow property of the process fluidcomprises a ratio of static pressure of the process fluid across theshock wave, wherein the ratio of static pressure of the process fluidacross the shock wave comprises an increase of as much as two or threetimes.
 4. The chemical reactor as claimed in claim 1, wherein thestationary diffuser section comprises a plurality of stationary diffuservanes positioned on a stationary diffuser hub, wherein the plurality ofstationary diffuser vanes are circumferentially spaced apart from eachother and extends radially outwardly from the stationary diffuser hubinto the flow path, and wherein each diffuser flow passage is definedcircumferentially between adjacent stationary diffuser vanes andradially between the stationary diffuser hub and the inner shroud. 5.The chemical reactor as claimed in claim 4, wherein a divergent rate ofeach diffuser flow passage is adjusted to provide the flow property ofthe process fluid across the shock wave.
 6. The chemical reactor asclaimed in claim 4, wherein the stationary diffuser section comprises atleast one aperture arranged on the stationary diffuser hub downstream ofthe shock wave, and wherein the aperture is configured to extract lowmolecule weight components from the process fluid.
 7. The chemicalreactor as claimed in claim 1, wherein the exhaust section comprises aplurality of stationary exhaust vanes positioned on a stationary exhausthub, wherein the plurality of stationary exhaust vanes arecircumferentially spaced apart from each other and extend radiallyoutward from the stationary diffuser hub into the flow path, and whereineach exhaust flow passage is defined circumferentially between adjacentstationary exhaust vanes and radially between the stationary exhaust huband the inner shroud. The chemical reactor as claimed in claim 1,further comprising a quenching zone arranged downstream of the impellersection, wherein the quenching zone comprises at least one nozzle forintroducing coolant flow into the process fluid.
 8. The chemical reactoras claimed in claim 7, wherein a convergent rate of each exhaust flowpassage is adjusted to provide the flow property of the process fluidacross the shock wave.
 9. The chemical reactor as claimed in claim 1,further comprising a quenching zone arranged downstream of the secondimpeller section, wherein the quenching zone comprises at least onenozzle for introducing coolant flow into the process fluid.
 10. A methodfor processing a process fluid comprising: providing a chemical reactorcomprising: an outer casing comprising a flow inlet for intaking theprocess fluid and a flow outlet for exiting the process fluid, wherein aflow path is defined within the outer casing extending axially along aninner shroud of the outer casing between the flow inlet and the flowoutlet; a rotary shaft extending into the outer casing and coupled to arotor disk, wherein the rotor shaft is driven by a power supply; a firstimpeller section and a second impeller section arranged downstream ofthe first impeller section, each impeller section comprising arespective plurality of rotating impeller blades positioned on the rotordisk, wherein the plurality of rotating impeller blades extends radiallyoutwardly from the rotor disk into the flow path; a stationary bucketsection arranged between the first impeller section and the secondimpeller section; a stationary diffuser section arranged downstream ofthe second impeller section, wherein the stationary diffuser sectioncomprises a plurality of divergent diffuser flow passages; a stationarydiffuser section arranged downstream of the impeller section, whereinthe stationary diffuser section comprises a plurality of divergentdiffuser flow passages; an exhaust section arranged downstream of thestationary diffuser section, wherein the exhaust section comprises aplurality of convergent exhaust flow passages, rotating the respectiveplurality of rotating impeller blades by the rotor shaft foraccelerating the process fluid to a supersonic flow; generating a shockwave in the stationary diffuser section by providing a back pressure,wherein the shock wave generated in the stationary diffuser sectionincreases a static temperature of the process fluid downstream of theshock wave to generate sufficient heat to process the process fluid; andprocessing the process fluid using a flow property of the process fluidacross the shock wave.
 11. The method as claimed in claim 10, whereinthe flow property of the process fluid comprises a ratio of statictemperature of the process fluid across the shock wave, wherein theratio of the static temperature of the process fluid across the shockwave is increased by at least ten percent.
 12. The method as claimed inclaim 10, wherein the flow property of the process fluid comprises aratio of static temperature of the process fluid across the shock wave,wherein the ratio of the static temperature of the process fluid acrossthe shock wave is increased by at least ten percent.
 13. The method asclaimed in claim 10, wherein the stationary diffuser section comprises aplurality of stationary diffuser vanes positioned on a stationarydiffuser hub, wherein the plurality of stationary diffuser vanes arecircumferentially spaced apart from each other and extend radiallyoutward from the stationary diffuser hub into the flow path, and whereineach diffuser flow passage is defined circumferentially between adjacentstationary diffuser vanes and radially between the stationary diffuserhub and the inner shroud.
 14. The method as claimed in claim 13, furthercomprising adjusting a divergent rate of each diffuser flow passage toprovide the flow property of the process fluid across the shock wave.15. The method as claimed in claim 14, wherein the stationary diffusersection comprises at least one aperture arranged on the stationarydiffuser hub downstream of the shock wave, and wherein the methodfurther comprising extracting low molecule weight components from theprocess fluid through the aperture.
 16. The method as claimed in claim10, wherein the exhaust section comprises a plurality of stationaryexhaust vanes positioned on a stationary exhaust hub, wherein theplurality of stationary exhaust vanes are circumferentially spaced apartfrom each other and extends radially outwardly from the stationarydiffuser hub into the flow path, and wherein each exhaust flow passageis defined circumferentially between adjacent stationary exhaust vanesand radially between the stationary exhaust hub and the inner shroud.17. The method as claimed in claim 16, further comprising adjusting aconvergent rate of each exhaust flow passage to provide the flowproperty of the process fluid across the shock wave. The method asclaimed in claim 17, further comprising adjusting a convergent rate ofeach exhaust flow passage to provide the flow property of the processfluid across the shock wave.
 18. The method as claimed in claim 10,further comprising arranging a quenching zone downstream of the secondimpeller section, wherein the quenching zone comprises at least onenozzle for introducing coolant flow into the process fluid. The methodas claimed in claim 11, further comprising arranging a quenching zonedownstream of the impeller section, wherein the quenching zone comprisesat least one nozzle for introducing coolant flow into the process fluid.19. The chemical reactor as claimed in claim 15, wherein a low moleculeweight component extracted from the process fluid through the at leastone aperture is hydrogen.